Apparatus and method for continuous motion rotatable forming of soluble pouches

ABSTRACT

A machine and method of forming multi-compartment pouches is disclosed in which two pouches formed on separate adjacent formers ( 1, 3 ) are brought together in register and the lidding webs ( 9, 15 ) of the pouches joined to form a combined pouch ( 33 ). The pouches may be held on the formers ( 1, 3 ) by vacuum until the pouches are joined whereupon the vacuum holding one of the pouches on its former ( 1 ) is released while maintaining the vacuum holding the other pouch on its former ( 3 ) so that the combined pouches ( 33 ) are held on that former by the vacuum until the vacuum is released.

This invention concerns improvements in or relating to continuous motion rotatable forming of soluble pouches. More especially, the invention concerns machines and methods for producing multi-compartment pouches from four soluble substrates.

In WO 2002/085736, a process has been described for producing a water-soluble container comprising at least two compartments by sealing together two single compartment pouches. The compartments may be formed by any method which produces an open container, for example by vacuum forming, thermoforming, blow moulding or injection moulding, and are adjacent to each other having been formed concurrently. The compartments are then filled with a composition and closed with a lid such that the compartments are joined by a folding portion. The folding portion is then folded such that the lids of each of the compartments adhere to each other. Any method of sealing the two compartments together may be used, including pressure as in a snap-fit, an adhesive such as an aqueous solution of PVOH, or heat sealing. Other methods of sealing include infra-red, radio frequency, ultrasonic, laser, solvent, vibration and spin welding are described. The adhesive can be applied to the lids by spraying, transfer coating, roller coating, or otherwise coating, or the lids can be passed through a mist of the adhesive. The folding portion may be subsequently removed in order to provide an even more attractive appearance.

The above process has disadvantages. The presence of a folding portion means that the at least two compartments must be adjacent to each other in order to allow subsequent folding. The process is difficult to scale up in order to achieve economies of scale as the folding and trimming process is cumbersome, particularly where the at least two compartments contain different products, and it is difficult to envisage how a folding mechanism can allow a number of compartments greater than two.

In one aspect the present invention provides a continuous motion machine for producing water-soluble pouches comprising two or more compartments from four water-soluble polymeric webs wherein two pouches are formed, filled and sealed on separate, adjacent donating and receiving formers, each pouch being formed from two water-soluble polymeric webs, and wherein the two such pouches are held by vacuum on their formers until they are joined together in register to form a combined pouch whereupon the vacuum in the donating former is removed releasing its pouch to the receiving former and the combined pouch still held by vacuum in the receiving former is separated from the combined web.

The water soluble substrates may comprise any suitable polymeric material such as those based substantially upon polyvinyl alcohol. The polymeric material may be extruded or cast in solution to form a web. The web may be a single or multi-layer water soluble film. The polymeric material may be approved for ingestion by humans and/or by animals.

It may be that the pouches are formed by two webs, a base web and a lidding web. The formers may have recesses to create open compartments or pouches in the base web by any suitable forming operation such as vacuum forming or thermoforming. The open compartments or pouches may be filled with one or more products before being closed by the lidding webs and then sealed or bonded together to form a combined web of sealed and filled closed pouches. The base webs preferably comprise polymeric material that is sufficiently elastic and of a sufficient thickness to allow it to be vacuum formed or thermoformed into the cavities of the respective former without being punctured.

It may be that the lidding web of a closed pouch on one former is only partially sealed or bonded to the lidding web of a closed pouch on the other former to form a combined pouch. As a result, an aqueous medium into which the combined pouch is placed may be able to penetrate between lidding webs of the closed pouches more quickly and thereby accelerate dissolution.

It may be that a perimetric seal is formed between the lidding webs of two pouches. The perimetric seal may be a partial seal or a complete seal.

It may be that the contents of each compartment are released into an aqueous medium at different times. Alternatively, the contents of each compartment may be released into an aqueous medium at substantially the same time.

It may be that a solid item is placed between lidding webs of the closed pouches before the lidding webs are sealed together, thereby creating a further compartment.

It may be that a device is provided for perforating one or more of the base webs.

It may be that the one or more base webs are perforated prior to forming open compartments or pouches.

It may be that the one or more base webs are perforated while forming open compartments or pouches.

It may be that the one or more base webs are perforated subsequent to forming open compartments or pouches.

It may be that different levels of vacuum can be applied at different positions around one or both formers. For example, when the pouches are combined and held on one former, the level of vacuum holding the combined pouch may be increased.

In another aspect the present invention provides a method of producing water-soluble pouches comprising two or more compartments by forming, filling and sealing two pouches on separate formers each from two water soluble substrates and joining the two such pouches together to form a combined pouch comprising two or more compartments.

The water soluble substrates may comprise any suitable polymeric material such as those based substantially upon polyvinyl alcohol. The polymeric material may be in the form of a web. The web may be a single or multi-layer water soluble film. The polymeric material may be approved for ingestion by humans and/or by animals.

It may be that the method uses a machine according to the preceding aspect of the invention.

It may be that one or more compartments contain a combination of at least two components comprising a granular or powder product, a thickened liquid or gel, and a three dimensional solid item such that all of the components retain their identity and none of the components become mutually antagonistic.

It may be that base webs of the pouches comprise a polymeric material that is sufficiently elastic and of a sufficient thickness to allow it to be vacuum formed or thermoformed into the cavities of the respective former without being punctured.

It may be that lidding webs of the pouches are only partially sealed or bonded together. In this way an aqueous medium into which a pouch is placed may be able to penetrate between lidding webs of the pouches more quickly and thereby enhance dissolution.

It may be that a perimetric seal is formed between the lidding webs of two pouches. The perimetric seal may be a partial seal or a complete seal.

It may be that one of the pouches is transferred from its rotatable former to a second rotatable former, the lidding webs of both pouches sealed or bonded together to form a joined pouch, and the joined pouches separated from the web.

It may be that the method includes forming a first web of pouches on a rotatable donating former, forming a second web of pouches on a rotatable receiving former, bringing the first and second webs of pouches together with pouches in the first web in register with pouches in the second web, joining the pouches in the first web to the pouches in the second web and removing the vacuum holding the pouches on the donating former to release the combined web of combined pouches from the donating former while the combined web of combined pouches is still held by vacuum on the receiving former, separating the combined pouches from the combined web and subsequently removing the vacuum holding the separated, combined pouches on the receiving former.

Each web of pouches may comprise a base web and a lidding web. The base web may be formed to provide open compartments or pouches to receive one or more components prior to closing the open compartments or pouches with the lidding web to form closed pouches. The lidding webs of the closed pouches on one former may be joined to the lidding webs of the closed pouches on the other former. The lidding webs may be joined by a perimetric seal. The perimetric seal may be a partial seal or a complete seal.

It may be that different levels of vacuum can be applied at different positions around one or both formers. For example, when the pouches are combined and held on one former, the level of vacuum holding the combined pouch may be increased.

In another aspect the present invention provides a water-soluble pouch comprising two or more compartments made by the machine or method according to the preceding aspects of the invention.

It may be that the pouches are only partially sealed or bonded together in order to enhance dissolution.

It may be that a solid component is inserted between the two pouches prior to the two pouches being sealed or bonded together.

In the present invention, the aforementioned disadvantages of WO 2002/085736 are overcome by a process in which the compartments are provided by independently forming, filling and sealing pouches on separate formers and then presenting the pouches to each other for sealing to form a multi-compartment pouch. In this way, the filled and sealed pouches providing the compartments may be accurately positioned one on top of the other and then sealed together to form the multi-compartment pouch. The rotatable formers may be of the type disclosed in our earlier patent application WO 2011/061628. In certain of the simplest embodiments of the present invention, the appearance of the finished product is not dissimilar to that produced by means of WO 2002/085736, but the process by which it has been made is different.

The machine and method of the preceding aspects of the invention produce pouches comprising two or more compartments from four water-soluble substrates. Two such substrates are needed to produce each independently formed compartment and a further compartment may be created between the two independently formed compartments immediately prior to sealing the two independently formed compartments together. One or more of the four substrates may be perforated. Each substrate may dissolve at the same temperature or pH. Alternatively, each substrate may, for example, dissolve at a different temperature or at a different pH in order to allow sequential release of the contents of each compartment. The water soluble substrates may comprise any suitable polymeric material such as those based substantially upon polyvinyl alcohol. The polymeric material may be in the form of a web. The web may be a single or multi-layer water soluble film. The polymeric material may be approved for ingestion by humans and/or by animals.

The thickness of each water-soluble substrate may vary according to:

-   -   1. The depth of forming of each base web and the volume of each         compartment     -   2. The type of fill, whether by way of example, a solid item,         powder, granules, liquid, thickened liquid, gel, hot molten         liquid, or other types of presentation     -   3. The desired dissolution time of each pouch     -   4. The quantity and/or pattern of solvent applied to each         lidding web prior to sealing of each compartment

The application of solvent to a lidding web prior to sealing reduces the strength of that web due to partial dissolution and re-plasticization or softening of the web. However, lidding webs may nevertheless typically be thinner than base webs as lidding webs are not subjected to a forming operation. In this invention, the lidding webs of each compartment are subsequently sealed together to form a combined web which may have a thickness more or less equal to the sum of the thicknesses of the two lidding webs. The thickness of the combined lidding webs can increase dissolution time. Where speed of dissolution is important, it may be desirable to minimize the thickness of each lidding web in order to minimize an increase in dissolution time. The double thickness of the seal or bond between the two pouches may be detrimental to the speed of dissolution of the joined pouch. In order to reduce any increase in dissolution time, the lidding webs may not be completely sealed together but only partially sealed together. This may be achieved by applying solvent only to part of the lidding web and/or applying heat and pressure only to part of the flange surrounding the compartment. By this means, the dissolution time may not necessarily increase as the aqueous medium into which the pouch is placed, will be able to penetrate more easily into the space between the two lidding webs. Subject always to the above speed of dissolution considerations, as much as possible of the periphery of the seal or bond between the two pouches may be sealed in order to enhance the attractiveness of the joined pouches.

It may be that the lidding webs of each compartment are superimposed one upon the other prior to sealing together the two compartments. It may be that the lidding webs of each compartment are brought together in such a way that one compartment is placed in a required position upon the second compartment. The first compartment may be symmetrically placed upon the second compartment but in some embodiments of the present invention, the first compartment may be asymmetrically placed upon the second compartment but nevertheless still in register. The process of bringing two pouches together in a required position relative to each other is referred to in the art as bringing the two pouches together in register. Bringing the two pouches together in register is desirable in order that the subsequent process of separating the two or more compartment pouches from each other by slitting in the machine direction and then in the transverse direction can be carried out effectively. Accurate registration of the two pouches prior to sealing together may also beneficial for the commercial attractiveness of a two or more compartment pouch. Accurate registration may be achieved by use of a separate servo drive on each former, one being a master and one being a slave.

The time taken for each compartment to release its contents into the aqueous medium into which a two or more compartment pouch according to this invention has been placed may be varied in order that the release time of the contents of each compartment is different. Such a sequential release may be of commercial value in applications where the contents of one pouch are required for immediate release and the contents of a second pouch are required at a later time.

A tablet or other solid object may be placed between the two pouches after each has been closed with a lidding web but before the two pouches are joined together. The contents of each compartment may be solid, granular or powder, liquid of any viscosity, or gel. In the case where one of the compartments contains a solid material, the placement of a tablet between two sealed pouches may be facilitated by providing the sealed pouch containing a solid material with a perforated base web allowing excess air to be drawn by vacuum from the sealed pouch prior to placement of a tablet in the greater space so created between the two sealed pouches.

The sealing or bonding of two pouches to form a combined pouch comprising two or more compartments is typically effected by a combination of pressure and partial or complete wetting, leading to adhesivity, of the external (top) surface of either of the lidding webs. The selection as to which lidding web is partially or completely wetted prior to sealing or bonding together of the two pouches will depend upon the thickness of the respective lidding webs and their dissolution properties. Either lidding web may be selected for application of the wetting agent. Typically, the less readily soluble of the respective lidding webs will be selected for wetting partially or completely prior to sealing or bonding together of the two pouches. Where the lidding webs are made from the same water-soluble polymer formulation, the lidding film which is selected for wetting is typically thicker than the unwetted lidding film. For example the wetted lidding film may be up to 50% thicker than the unwetted lidding film.

During the process by which the two pouches are combined together into a multi-compartment pouch, the vacuum holding each pouch in its respective pocket is regulated and controlled. The vacuum in the pockets of the donating former is maintained, for example by means of a precisely designed and positioned vacuum shoe, until the two pouches have been combined together at which precise point the vacuum of the donating former is released. Conversely, the vacuum in the pockets of the receiving former is maintained whilst the two pouches are combined together and thereafter whilst the joined multi-compartment pouches, by now joined together in a combined web, are transported to a cutting station on the receiving former where they are separated from each other, for example by knives mounted in both machine direction and transverse direction, and the vacuum is subsequently released allowing the joined multi-compartment pouches to fall off or be blown off the receiving former on to a moving conveyor which transports the web of multi-compartment pouches to a downstream packaging operation. Once the multi-compartment pouches have been separated from each other, the side trim from the web is drawn by vacuum or otherwise into a collecting system for disposal or recycling.

In another aspect, the present invention provides a multi-compartment water-soluble pouch produced from four water-soluble webs comprising a first water-soluble pouch and a second water-soluble pouch wherein a compartment is created between the two pouches.

It may be that a solid object such as a tablet or a water-soluble pouch or capsule made off-line is inserted into the compartment between the two pouches.

It may be that the two pouches are sealed or bonded together by means of a partial perimetric seal.

It may be that the two pouches are sealed or bonded together by means of a complete perimetric seal.

It may be that at least one of the compartments of the first or second water-soluble pouch is perimetric.

It may be that the seal pressure exerted between the first and second water-soluble pouches is adjustable.

Features of any of the preceding aspects of the invention may be employed separately or in combination with the same or different aspects of the invention,

The invention will now be described in more detail by way of example with reference to the accompanying drawings wherein:

FIG. 1 shows a machine according to a first embodiment of the invention;

FIG. 2 shows a machine according to a second embodiment of the invention;

FIG. 3 shows a machine according to a third embodiment of the invention;

FIGS. 4 a and 4 b are plan and sectional views of a multi-compartment pouch produced by the machines of FIGS. 1 to 3;

FIG. 5 shows a machine for producing multi-compartment pouches according to a fourth embodiment of the invention;

FIGS. 6 a and 6 b are plan and sectional views of a multi-compartment pouch produced by the machine of FIG. 5;

FIGS. 7 a, 7 b show plan and sectional views of an alternative multi-compartment pouch according to the invention;

FIGS. 8 a, 8 b show plan and sectional views of an alternative multi-compartment pouch according to the invention;

FIGS. 9 a, 9 b show plan and sectional views of an alternative multi-compartment pouch according to the invention;

FIGS. 10 a, 10 b, 10 c, 10 d show plan, perspective and sectional views of an alternative multi-compartment pouch according to the invention;

FIGS. 11 a, 11 b show plan and sectional views of an alternative multi-compartment pouch according to the invention;

FIGS. 12 a, 12 b show plan and sectional views of an alternative multi-compartment pouch according to the invention;

FIGS. 13 a, 13 b show plan and sectional views of an alternative multi-compartment pouch according to the invention;

FIGS. 14 a, 14 b, 14 c show plan, perspective and sectional views of an alternative multi-compartment pouch according to the invention;

FIGS. 15 a, 15 b show plan and sectional views of an alternative multi-compartment pouch according to the invention;

FIGS. 16 a, 16 b, 16 c show plan, perspective and sectional views of an alternative multi-compartment pouch according to the invention;

FIGS. 17 a, 17 b, 17 c show an alternative method of wetting the lidding webs;

FIGS. 18 a, 18 b show an alternative method of wetting the lidding webs;

FIGS. 19 a, 19 b show an alternative method of wetting the lidding webs; and

FIGS. 20 a and 20 b shows a method of inserting a solid object between the lidding webs and a pouch so formed.

In the following description of exemplary embodiments, terms such as top, bottom, upper, lower, horizontal are used with reference to the orientation of the embodiments depicted in the drawings are not limiting on the scope of the embodiments.

In the exemplary embodiment of FIG. 1, multi-compartment pouches are produced by forming two webs of closed pouches and joining the webs together whereby the pouches in one web are superposed in register on the pouches in the other web using two continuously rotatable formers 1, 3. Each former 1, 3 is similar and has a forming surface 1 a, 3 a that is circular, for example a continuously rotating drum containing pockets 1 b, 3 b. Further details of the construction and operation of each former 1, 3 can be obtained by referring to the description in our earlier application WO2011/061628 to which the reader is directed and only features necessary for an understanding of the present invention are described in the following description.

As shown in FIG. 1, a plurality of open compartments or pouches is formed in the pockets or recesses 1 b in the circular forming surface 1 a of the former 1 by a first water soluble polymeric web 5. The open pouches are filled via a product feed 7 and then closed by a second water soluble polymeric web 9 to form a first web of closed pouches. A plurality of open compartments or pouches is formed in the pockets or recesses 3 b in the circular forming surface 3 a of the former 3 by a third water soluble polymeric web 11. The open pouches are filled via a product feed 13 and then closed by a fourth water soluble polymeric web 15 to form a second web of closed pouches. The first and third polymeric webs 5, 11 are base webs and the second and fourth polymeric webs 9, 15 are lidding webs for the open pouches formed by the first and third base webs 5, 11. The lidding webs 9, 15 are wetted via wetting rollers 17, 19 to provide adhesion to the first and third base webs 5, 11 to produce the first and second webs of closed pouches on the formers 1, 3. Sealing rollers 21, 23 are provided to seal the lidding webs 9, 15 to the first and third base webs 5, 11. The pouches may be vacuum or thermoformed. The pouches may be held on the formers 1, 3 by a vacuum applied through the pockets in the formers 1, 3 as described in WO 2011/061628.

An additional wetting roller 25 is provided for wetting the external (top) surface of the lidding web 9 of the first web of closed pouches on the former 1 to be wetted prior to being brought into contact with the external (top) surface of the lidding web 15 of the second web of closed pouches on the former 3 at 27. The lidding web 9 may be partially or completely wetted in order to produce adhesivity when the lidding webs 9, 15 of the two webs of closed pouches are brought together at 27. At 27, the lidding webs 9, 15 are sealed or bonded together by a combination of pressure exerted between the two rotating formers 1, 3 and the adhesivity of the external (top) surface of the lidding web 9 produced by the action of the wetting roller 25. As a result, the first and second webs of closed pouches are combined together with closed pouches in the first web of pouches aligned with and in register with closed pouches in the second web of pouches to produce multi-compartment combined pouches from the pouches in both webs. In an alternative arrangement (not shown), the external (top) surface of the lidding web 15 of the second web of closed pouches may be partially or completely wetted prior to being brought into contact with the external (top) surface of the lidding web 9 of the first web of closed pouches at 27 to provide adhesion to the second web of closed pouches. Alternatively, the external (top) surface of both lidding polymeric webs 9, 15 may be wetted prior to being brought together to provide adhesion between the combined webs of closed pouches.

During the process by which the multi-compartment pouches are formed, the vacuum holding each pouch in its respective pocket is regulated and controlled. The vacuum is maintained, until the two pouches have been joined together at which point the vacuum in the pockets of one of the formers (the donating former) is released while the vacuum in the pockets of the other former (the receiving former) is maintained. In this way the combined web of multi-compartment pouches formed by combining the webs of pouches on both formers is retained by the receiving former. In this embodiment, former 1 is the donating former and former 3 is the receiving former but this could be reversed with former 3 being the donating former and former 1 the receiving former.

The multi-compartment pouches so formed can be separated from the combined webs at a cutting station on the receiving former 3 where they are separated from each other by any suitable device 29 for example cutting the combined webs in both the longitudinal direction and the transverse direction with a blade or knife or laser as will be familiar to those skilled in the art and the vacuum holding the pouches in the pockets 3 b subsequently released allowing the joined multi-compartment pouches to fall off the receiving former 3 on to a moving conveyor 31 which transports the multi-compartment pouches 33 to a packaging operation. Once the multi-compartment pouches 33 have been separated from each other, the side trim from the web may be drawn by vacuum or otherwise into a collecting system for disposal or recycling. Transfer of the pouches may be assisted by applying fluid pressure through holes in the base of the pockets to eject the pouches from the pockets. The fluid may be air or any other fluid inert to the water-soluble substrates of the pouches.

The pressure exerted between the two rotating formers 1, 3 and/or the adhesivity of the external (top) surface of the lidding polymeric web(s) may be adjusted according to the required quality of the seal or bond between the two webs of pouches. If a partial seal or bond is required in order to enhance speed of dissolution of the combined pouch, this can be obtained by means of an engraved wetting roller such that the external (top) surface of the lidding web(s) is not completely covered but only partially covered, resulting in a partial seal or bond between the lidding web(s) at 27.

The thicknesses and dissolution or other characteristics of the four polymeric webs 5, 9, 11, 15 may be identical or different according to any one or more of the following list of features given by way of non-limiting example only:

-   -   the size of the compartments     -   the material contained within each compartment     -   the release time of each compartment by which we mean the time         for each compartment (for the avoidance of doubt, the release         time of each compartment need not necessarily be the same) to         have released its contents into an aqueous medium into which the         multi-compartment pouch is placed.     -   the time to complete dissolution of each compartment.

In FIG. 1, the former 1 is shown above and offset to one side of the former 3 allowing the webs of open pouches on both formers to be filled and closed at the top of the formers 1, 3 thereby increasing the available volume that can be filled without spillage, especially when introducing a flowable product into the open pouches. It will be understood however, that other arrangements of the formers may be employed, whereby, for example the formers may be arranged one above and offset to the other side as well as the offset arrangement shown in FIG. 1. By the term offset in this context, we mean any arrangement in which the sealing or bonding of the combined pouch takes place (with reference to FIG. 1) between 9 o'clock and 11 o'clock provided that sufficient space remains between 11 o'clock and 1 o'clock for a filling station to be positioned.

In FIG. 1, the diameter of the drums of each former 1, 3 is shown to be identical. However, it will be understood that it is not essential for the drum diameters of each former to be identical. Indeed, there may be advantages to make the drum diameters different. For example by making the diameter of the lower former greater than that of the higher former a greater distance may be available around the circumference of the lower former in which to fit one or more filling stations and one or more cutting stations.

In the exemplary embodiment of FIG. 2, the same principle as described above for FIG. 1 is applied to a different configuration of continuously rotatable formers. For convenience, like reference numerals in the series 100 are used to indicate the same or similar parts.

In FIG. 2, the first former 101 has a forming surface 101 a that is circular, for example a continuously rotating drum containing pockets 101 b, and the second former 103 has a forming surface 103 a that is flat, typically horizontal, for example a continuously rotatable endless chain or belt containing pockets 103 b. Further details of the construction and operation of each former 101, 103 can be obtained by referring to the description in our earlier application WO2011/061628 to which the reader is directed and only features necessary for an understanding of the present invention are described in the following description.

As shown in FIG. 2, a plurality of open compartments or pouches is formed in the pockets 101 b in the circular forming surface 101 a of the former 101 by the water soluble base web 105. The open pouches are filled via product feed 107 and then closed by the second water soluble web 109 to form a first web of closed pouches. A plurality of open compartments or pouches is formed in the pockets 103 b in the horizontal forming surface 103 a by a third water soluble web 111. The open pouches are filled via a product feed 113 and then closed by a fourth water soluble web 115 to form a second web of closed pouches. The first and third webs 105, 111 are base webs and the second and fourth webs 109, 115 are lidding webs for the open pouches formed by the first and third base webs 105, 111. The lidding webs 109, 115 are wetted via wetting rollers 117, 119 to provide adhesion to the first and third base webs 105, 111 to produce the first and second webs of closed pouches on the formers 101, 103. Sealing rollers 121, 123 are provided to seal the lidding webs 109, 115 to the first and third base webs 105, 111. The first and second webs of closed pouches so formed are held in place on the formers 101, 103 by applying vacuum through the pockets in the forming surfaces of the formers as described in WO 2011/061628.

An additional wetting roller 125 is provided for wetting the external (top) surface of the lidding web 109 of the first web of closed pouches on the former 101 to be wetted prior to being brought into contact with the external (top) surface of the lidding web 115 of the second web of closed pouches on the former 103 at 127. The lidding polymeric web 109 may be partially or completely wetted in order to produce adhesivity when the lidding polymeric webs 109, 115 of the two webs of closed pouches are brought together at 127. At 127, the lidding webs 109, 115 are sealed or bonded together by a combination of pressure exerted between the two rotating formers 101, 103 and the adhesivity of the external (top) surface of the lidding web 109 produced by the action of the wetting roller 125. As a result, the first and second webs of closed pouches are combined together with closed pouches in the first web of pouches aligned with and in register with closed pouches in the second web of pouches to produce multi-compartment combined pouches 133 from the pouches in both webs. In an alternative arrangement (not shown), the external (top) surface of the lidding web 115 of the second web of closed pouches may be partially or completely wetted prior to being brought into contact with the external (top) surface of the lidding web 109 of the first web of closed pouches at 127 to provide adhesion to the second web of closed pouches. Alternatively, the external (top) surface of both lidding webs 109, 115 may be wetted prior to being brought together to provide adhesion between the combined webs of closed pouches.

As described previously, the vacuum holding the first web of pouches on the donating former 101 is released during the sealing or bonding process while maintaining the vacuum holding the second web of pouches on the receiving former 103 so that the multi-compartment pouches formed by the combined webs are retained on the receiving former 103 and can be separated from the combined webs by any suitable device 129 for example cutting with a blade or knife or laser as will be familiar to those skilled in the art and released from the receiving former 103 on to a conveyor (not shown) or similar arrangement for delivering the individual multi-compartment combined pouches 133 to a collection point (not shown) for a packaging operation or other processing as required. In a modification, the former 101 may be the receiving former and the former 103 may be the donating former. In this arrangement the vacuum holding the second web of pouches on the donating former 103 may be released while maintaining the vacuum holding the first web of pouches on the receiving former 101 so that the combined webs are retained on the receiving former 101 and can be separated and delivered to a collection point as described previously.

The pressure exerted between the two rotatable formers 101, 103 and/or the adhesivity of the external (top) surface of the lidding web(s) may be adjusted according to the required quality of the seal or bond between the two webs of pouches. If a partial seal or bond is required in order to enhance speed of dissolution of the combined pouch, this can be obtained by means of an engraved wetting roller such that the external (top) surface of the lidding web(s) is not completely covered but only partially covered, resulting in a partial seal or bond between the lidding webs at 127. In FIG. 2 the circular forming surface 101 a of the donating former 101 is positioned above the horizontal forming surface 103 a of the receiving former 103 and the first and second webs of closed pouches are brought together so that the closed pouches in the web on the donating former 101 are positioned above and in register with the closed pouches in the web on the receiving former 103. As a result, the first and second webs of closed pouches are combined together to produce multi-compartment combined pouches from the pouches in both webs.

The thicknesses and dissolution or other characteristics of the four polymeric webs 105, 109, 111, 115 may be identical or different according to any one or more of the following list of features given by way of non-limiting example only:

-   -   the size of the compartments     -   the material contained within each compartment     -   the release time of each compartment by which we mean the time         for each compartment (for the avoidance of doubt, the release         time of each compartment need not necessarily be the same) to         have released its contents into an aqueous medium into which the         multi-compartment pouch is placed.     -   the time to complete dissolution of each compartment.

In the exemplary embodiment of FIG. 3, the same principle as described above for FIGS. 1 and 2 are applied to another different configuration of continuously rotatable formers. For convenience, like reference numerals in the series 200 are used to indicate the same or similar parts.

In FIG. 3, both the first former 201 and the second former 203 have forming surfaces 201 a, 203 a that are flat, typically horizontal, for example a continuously rotatable endless chain or belt containing pockets 201 b, 203 b. Further details of the construction and operation of each former 201, 203 can be obtained by referring to the description in our earlier application WO2011/061628 to which the reader is directed and only features necessary for an understanding of the present invention are described in the following description.

As shown in FIG. 3, a plurality of open compartments or pouches is formed in the pockets 201 b in the horizontal forming surface 201 a of the former 201 by the water soluble base web 205. The open pouches are filled via product feed 207 and then closed by the second water soluble web 209 to form a first web of closed pouches. A plurality of open compartments or pouches is formed in the pockets 203 b in the horizontal forming surface 203 a by a third water soluble web 211. The open pouches are filled via a product feed 213 and then closed by a fourth water soluble web 215 to form a second web of closed pouches. The first and third webs 205, 211 are base webs and the second and fourth webs 209, 215 are lidding webs for the open pouches formed by the first and third base webs 205, 211. The lidding webs 209, 215 are wetted via wetting rollers 217, 219 to provide adhesion to the first and third base webs 205, 211 to produce the first and second webs of closed pouches on the formers 201, 203. Sealing rollers 221, 223 are provided to seal the lidding webs 209, 215 to the first and third base webs 205, 211. The first and second webs of closed pouches so formed are held in place on the formers 201, 203 by applying vacuum through the pockets in the forming surfaces of the formers as described in WO 2011/061628.

An additional wetting roller 225 is provided for wetting the external (top) surface of the lidding web 209 of the first web of closed pouches on the former 201 to be wetted prior to being brought into contact with the external (top) surface of the lidding web 215 of the second web of closed pouches on the former 203 at 227. The lidding polymeric web 209 may be partially or completely wetted in order to produce adhesivity when the lidding polymeric webs 209, 215 of the two webs of closed pouches are brought together at 227. At 227, the lidding webs 209, 215 are sealed or bonded together by a combination of pressure exerted between the two rotating formers 201, 203 and the adhesivity of the external (top) surface of the lidding web 209 produced by the action of the wetting roller 225. As a result, the first and second webs of closed pouches are combined together with closed pouches in the first web of pouches aligned with and in register with closed pouches in the second web of pouches to produce multi-compartment combined pouches from the pouches in both webs. In an alternative arrangement (not shown), the external (top) surface of the lidding web 215 of the second web of closed pouches may be partially or completely wetted prior to being brought into contact with the external (top) surface of the lidding web 209 of the first web of closed pouches at 227 to provide adhesion to the second web of closed pouches. Alternatively, the external (top) surface of both lidding webs 209, 215 may be wetted prior to being brought together to provide adhesion between the combined webs of closed pouches.

As described previously, the vacuum holding the first web of pouches on the donating former 201 is released during the sealing or bonding process while maintaining the vacuum holding the second web of pouches on the receiving former 203 so that the multi-compartment combined pouches 233 so formed by the combined webs are retained on the receiving former 203 and can be separated from the combined webs by any suitable device 229 for example cutting with a blade or knife or laser as will be familiar to those skilled in the art and released from the receiving former 203 on to a conveyor (not shown) or similar arrangement for delivering the individual multi-compartment pouches to a collection point (not shown) for a packaging operation or other processing as required. In a modification, the former 201 may be the receiving former and the former 203 may be the donating former. In this arrangement the vacuum holding the second web of pouches on the donating former 203 may be released while maintaining the vacuum holding the first web of pouches on the receiving former 201 so that the combined webs are retained on the receiving former 201 and can be separated and delivered to a collection point as described previously.

The pressure exerted between the two rotatable formers 201, 203 and/or the adhesivity of the external (top) surface of the lidding web(s) may be adjusted according to the required quality of the seal or bond between the two webs of pouches. If a partial seal or bond is required in order to enhance speed of dissolution of the combined pouch, this can be obtained by means of an engraved wetting roller such that the external (top) surface of the lidding web(s) is not completely covered but only partially covered, resulting in a partial seal or bond between the lidding web(s) at 227. In FIG. 3 the horizontal forming surface 201 a of the donating former 201 is positioned above the horizontal forming surface 203 a of the receiving former 203 and the first and second webs of closed pouches are brought together so that the closed pouches in the web on the donating former 201 are positioned above and in register with the closed pouches in the web on the receiving former 203. As a result, the first and second webs of closed pouches are combined together to produce multi-compartment combined pouches from the pouches in both webs.

The thicknesses and dissolution or other characteristics of the four polymeric webs 205, 209, 211, 215 may be identical or different according to any one or more of the following list of features given by way of non-limiting example only:

-   -   the size of the compartments     -   the material contained within each compartment     -   the release time of each compartment by which we mean the time         for each compartment (for the avoidance of doubt, the release         time of each compartment need not necessarily be the same) to         have released its contents into an aqueous medium into which the         multi-compartment pouch is placed.     -   the time to complete dissolution of each compartment.

In an exemplary embodiment, the sealing pressure exerted by the formers 1, 3 (FIG. 1) or 101, 103 (FIG. 2) or 201, 203 (FIG. 3) can be adjusted to obtain a desired strength of the seal between the two pouches. Different films or different pouch designs may require different sealing pressures

The machine preferably has a main frame to which the both formers 1, 3 (FIG. 1) or 101, 103 (FIG. 2) or 201, 203 (FIG. 3) can be mounted in order to achieve the initial adjustment of the sealing pressure between the two pouches. To achieve variable seal pressures, the top former is preferably mounted on a separate sub frame which is movable in a vertical direction in order to provide seal pressure adjustment. The weight of the sub-frame is preferably supported by springs, pneumatic or hydraulic cylinders, air springs or servo-controlled actuators or other similar means. Seal pressure adjustment may be achieved by tightening one or more adjusters such as micro screws against the spring force allowing a precise and repeatable adjustment. Seal pressure may be remotely controlled by an operator, for example by means of a read out on a main display panel. The adjusters, for example micro screws, may be powered, for example by small servo or stepping motors. The seal pressure exerted during the process of sealing the two pouches may be monitored, for example by one or more load sensors at the sealing surface, and a digital signal representative of the sealing pressure may be provided, for example at the main display panel, allowing the operator to adjust the seal pressure by the above mentioned adjusters, for example micro screws.

When the top former sub frame is installed, the pressure at the sealing surface may be measured and used to calibrate the pressure load sensors for repeatability. Then, by means of a series of test runs with different setting combinations, sets of sample pouches may be produced and evaluated for seal quality and integrity, establishing a baseline against which future production can be monitored. Data sets from the series of test runs can then be used to determine the best combination of parameters for the pouch production. In addition, the drum may be mounted so that a skew angle of the drum to the chain can be micro-adjusted—to compensate for (or, in some cases, create) misalignment for appearance effect.

Sealing of the two pouches can be achieved by several different methods, depending on the pouch design/appearance requirement. For example, an incomplete or partial circumferential seal (stitch sealing) between the two pouches can be produced by different methods. One such method may include placing a series of liquid droplets on the mating surface of one or other of the pouches. The volume of each droplet can be precisely measured by the use of precision nozzles. The number of liquid droplets and the location and timing of placing the liquid droplets on the mating surface of one or other pouch, can be calculated depending on the machine speed, and the pressure and temperature selected to make an optimum strength seal. A dedicated screen can be provided for this task to take account of the temperature, humidity and other parameters of the environment of the production room where manufacturing is taking place. In this way, the quality of the stitched seal between the two pouches can be repeated even when environmental factors change, for example, due to a change in the environment of the production room or due to machine relocation to a different facility.

The same nozzles can be utilized if a complete circumferential seal between the pouches if desired. A complete circumferential seal can be provided by changing the pattern and volume of the droplets. In the case where an integral seal is desired, by which we mean that the entire mating surface of one of the pouches is wetted prior to the two pouches being brought together to be sealed, a wetting roller can be provided for this purpose. However, the use of nozzles is preferable as it can be used to provide either “stitched” or complete circumferential seals whereas the use of a wetting roller requires a change in the set up of the machine and consequential loss of productivity and flexibility.

A silicone or natural rubber gasket placed around the open pockets of one or both of the rotatable formers may facilitate greater control of the sealing pressure.

An example of a multi-compartment pouch 151 formed by the machines shown in FIGS. 1, 2 and 3 is shown in FIGS. 4 a and 4 b. The materials contained within the compartments are not shown for convenience and clarity. In this embodiment, there are two compartments A and B comprised within the combined pouch when the two webs of closed pouches are brought together and joined.

In FIG. 5, a modification of the machine of FIG. 2 is shown whereby the machine is converted to form multi-compartment pouches by a different mode of operation. For convenience and clarity, like reference numerals are used to indicate the same or similar parts and some parts of the machine shown in FIG. 2 are omitted or depicted diagrammatically.

As shown in FIG. 5, a plurality of open compartments or pouches are formed in the pockets 103 b in horizontal forming surface 103 a of the former 103 by the water soluble polymeric web 111 as described previously for FIG. 2. The open pouches are filled via product feed 113 but, unlike the mode of operation described previously for FIG. 2, the open pouches are closed by a web of already closed pouches formed in the pockets (not shown) in the circular forming surface 101 a of the former 101. The webs of open and closed pouches are brought together at 127 and combined by wetting (not shown) the external (top) surface of the lidding web 109 of the web of closed pouches so as to provide adhesivity to the base web 111 of open filled pouches around the perimeter of the open pouches so as to close the open pouches. Depending on the contents of the open pouches, the lidding polymeric web 109 may be wetted to provide selective adhesivity to the polymeric web 111 by which term we mean to close completely or partially (for example, by means of a “stitched” seal) the open pouches. As a result, the web of open pouches and the web of closed pouches are combined together in register at 127 to produce multi-compartment pouches comprising three water-soluble substrates from the pouches in both webs. A further water-soluble polymeric web 115 is then sealed or bonded to the combined webs at 135 to provide a further compartment aligned with and in register with the compartments formed at 127 by the pouches in the combined webs, prior to separating the resulting multi-compartment pouches from the combined webs as described previously for FIG. 2. A similar modification may be employed in the machine shown in FIG. 3.

An example of a multi-compartment pouch formed by the machine shown in FIG. 5 is illustrated in FIGS. 6 a and b. In this embodiment, there are three compartments A, B and C. Compartments A and B are produced by the superimposed pouches when the two webs are brought together and joined at 127. Compartment C is produced when the polymeric web 115 is joined to the combined webs at 135. Compartment C formed by the polymeric web 115 may be empty in order to enhance the appearance of the multi-compartment pouch.

As will be appreciated, four water soluble substrates are used to produce the multi-compartment pouches formed by the mode of operation of the machines shown in FIGS. 1, 2 and 3 and by the mode of operation of the machine shown in FIG. 5. The reconfiguration of the machine shown in FIG. 2 to provide the mode of operation shown in FIG. 5 is simply performed by moving the unwind for the water-soluble polymeric web 115 from its position upstream of the circular forming surface 101 a in FIG. 2 to a position downstream of the circular forming surface 101 a in FIG. 5.

Further examples of novel multi-compartment pouches that can be made using the machine and the method described herein are shown in FIGS. 7 a, 7 b through FIGS. 16 a, 16 b. Each pouch has been made by combining two pouches each made from two water-soluble polymeric webs and therefore comprises four separate water-soluble substrates. The first and second pouches can contain a single compartment containing, for example, a powder formulation, a granular formulation, a liquid formulation, a gel formulation, or a molten formulation. Alternatively, one or other or both of the first and second pouches can comprise more than one compartment each containing either a single formulation as described above or a plurality of different formulations, for example, a first molten formulation able to become solidified quickly enough for a second formulation to be inserted thereupon without mutual antagonism developing between the first and second formulations. These examples are not to be taken as limiting as many combinations of the principles illustrated in these examples can be made.

In FIGS. 7 a, 7 b, a first pouch comprising a single compartment A is sealed to a second pouch comprising a single compartment B but immediately prior to sealing, a third compartment H is created between the first and second pouches by the insertion of component E which, for example, may be a solid object such as a tablet or a water-soluble pouch or capsule which has been made off-line and inserted between the first and second pouches by the machine of the present invention. Note that compartment H is empty except for the presence of component E and that the two pouches are similar in profile providing a symmetrical appearance to the combined pouch comprising three compartments.

In FIGS. 8 a, 8 b, the construction of the first and second pouches are similar to those illustrated in FIGS. 7 a, 7 b, but here, component E is inserted into compartment A of the first pouch and component F is inserted into compartment B of the second pouch respectively prior to each pouch being sealed with a second web of water-soluble film. Unlike the example illustrated in FIGS. 7 a, 7 b, a third compartment is no longer created between the two pouches when the first and second pouches are sealed together to form a combined pouch. Note that the two pouches are similar in profile providing a symmetrical appearance to the combined pouch comprising two compartments with each compartment (A and B) containing two components.

In FIGS. 9 a, 9 b, the construction of the combined pouch is similar to that illustrated in FIGS. 7 a, 7 b but here the first and second pouches comprise two compartments each, instead of the single compartments shown in FIGS. 7 a, 7 b. The first pouch comprises compartments A and B and the second pouch comprises compartments C and D. Component E is inserted between the first and second pouches creating a further compartment H according to the same method described above for FIG. 7 a, 7 b. It should be noted that in FIGS. 9 a, 9 b, compartments B and D are perimetric compartments that surround the central compartments A and C. Note that the two pouches are again similar in profile providing a symmetrical appearance to the combined pouch which, in this example, comprises five compartments A, B, C, D and H.

In FIGS. 10 a, 10 b, 10 c, 10 d a modification of the pouch illustrated in FIGS. 9 a, 9 b is shown in which the central compartment of each pouch has been removed in order to allow the presence of component E to be clearly visible within compartment H through the water-soluble film windows W1 and W2 which replace the central compartments A and C. In this example, the compartments B and D are perimetric compartments that surround the central windows W1, W2 through which component E becomes visible. Note that the two pouches are similar in profile providing a symmetrical appearance to the combined pouch which, in this example, comprises three compartments, B, D, and H.

By the term perimetric compartment in FIGS. 9 a, 9 b and FIGS. 10 a, 10 b, 10 c, 10 d we mean a compartment situated around the perimeter of, and therefore surrounding, preferably without interruption, a central compartment, shown in FIG. 9 b as compartments A and C or a central window, shown in FIG. 10 b as windows W1 and W2. Perimetric compartments could be described as annular were they to be circular in plan view. Note that the two pouches are again similar in profile providing a symmetrical appearance to the combined pouch comprising five compartments in the case of the combined pouch shown in FIGS. 9 a, 9 b and three compartments in the case of the combined pouch shown in FIGS. 10 a, 10 b, 10 c, 10 d.

In FIGS. 11 a, 11 b, the construction of the combined pouch is similar to that illustrated in FIGS. 9 a, 9 b but here component E is not inserted between the pouches allowing the first and second pouches to touch each other throughout the mating surfaces by which term is meant the area of each pouch in contact with the other during the sealing process. Note that the two pouches are similar in profile providing a symmetrical appearance to the combined pouch which, in this example, comprises four compartments, A, B, C and D with compartments B and D being perimetric compartments that surround central compartments A and C.

In FIGS. 12 a, 12 b, the construction of the first pouch (the upper pouch as viewed in the drawing) is similar to that shown in FIG. 11 b with a perimetric compartment D that surrounds central compartment C but, in this example, the second pouch (the lower pouch as viewed in the drawing) is no longer a mirror image of the first pouch. The second pouch comprises a single compartment A extending to the perimeter seal. Note that the two pouches are dissimilar in profile providing an asymmetrical appearance to the combined pouch which comprises three compartments, A, C and D.

In FIGS. 13 a, 13 b, the construction of the first pouch (the upper pouch as viewed in the drawing) is again similar to that shown in FIG. 11 b with a perimetric compartment D that surrounds central compartment C but, in this example, the second pouch (the lower pouch as viewed in the drawing) is again no longer a mirror image of the first pouch. The second pouch comprises a single perimetric compartment B that surrounds a central window W allowing visible access to compartment C of the first pouch. Note that the two pouches are dissimilar in profile providing an asymmetrical appearance to the combined pouch which comprises three compartments B, C and D.

In FIGS. 7 a, 7 b through FIGS. 13 a, 13 b the first and second pouches are generally circular or elliptical in plan view. This is not essential.

In FIGS. 14 a, 14 b, 14 c the first and second pouches are similar to that shown in FIGS. 12 a, 12 b, but in this example the pouches are rectangular in plan view allowing each of the three compartments A, C and D to assume a rectangular shape. This has the benefit that each compartment fills a greater percentage of the available web surface area, thereby reducing the flange area surrounding compartments A and C and avoiding the need for removal of waste from the flange area. Note that the two pouches are dissimilar in profile providing an asymmetrical appearance to the combined pouch which comprises three compartments, A, C and D.

In FIGS. 15 a, 15 b the first and second pouches are similar to that shown in FIGS. 9 a, 9 b but, in this example the pouches are triangular in plan view. Note that the two pouches are similar in profile providing a symmetrical appearance to the combined pouch which comprises four compartments, A, B, C and D.

Other shapes of pouches may be employed. For example, perimetric compartments comprising two half circles joined by straight lines thereby forming a “racetrack” in plan view.

In FIGS. 9 a, 9 b through FIGS. 15 a, 15 b, the perimetric compartments comprise a single compartment that completely surrounds either a central compartment or a window. This is not essential.

In FIGS. 16 a, 16 b, 16 c, the construction of the second pouch is similar to that shown in FIGS. 8 a, 8 b but, in this example, the perimetric compartment of the first pouch is divided into two semi-perimetric compartments, B and D. In FIGS. 16 a, 16 b, 16 c, we show an example where compartments B and D are equal in size although this is not necessary as the two compartments B and D may be unequal in size. Note that the two pouches are dissimilar in profile providing an asymmetrical appearance to the combined pouch which comprises four compartments, A, B, C and D.

Other configurations of perimetric compartments may be employed. For example the single perimetric compartments shown in FIGS. 9 a, 9 b through FIGS. 15 a, 15 b may be divided into two or more partly perimetric compartments of the same or different shape.

The following table provides a summary of features of the pouches described herein.

Component Number of Number of between Perimetric Inserted WSP Webs Compartments Pouches Symmetrical compartment Component FIGS. 4a, 4b 4 2 No Yes No FIGS. 6a, 6b 4 3 No No No FIGS. 7a, 7b 4 3 Yes Yes No A solid object such as a tablet or a water-soluble pouch or capsule made off line FIGS. 8a, 8b 4 2, each containing No Yes No two components FIGS. 9a, 9b 4 5 Yes Yes Yes around both pouches A solid object such as a tablet or a water-soluble pouch or capsule made off line FIGS. 10a, 10b, 4 3 Yes Yes Yes around both pouches A solid object such as a 10c. 10d tablet or a water-soluble pouch or capsule made off line FIGS. 11a, 11b 4 4 No Yes Yes around both pouches FIGS. 12a, 12b 4 3 No No Yes around first pouch FIGS. 13a, 13b 4 3 No No Yes around first pouch FIGS. 14a, 14b, 4 3 No No Yes around first pouch 14c FIGS. 15a, 15b 4 4 No Yes Yes, around both pouches FIGS. 16a, 16b, 4 4 No No Yes, around first pouch but 16c divided into two compartments

Referring now to FIGS. 17 a, 17 b, 17 c, FIGS. 18 a, 18 b and FIGS. 19 a, 19 b, different methods are illustrated of wetting the external (top) surface of the lidding web of sealed pouches on one former prior to sealing or bonding to the lidding web of sealed pouches on the other former to produce combined water-soluble pouches containing two or more compartments. These illustrations are by no means limiting of methods of wetting the external (top) surface of either lidding web to obtain the desired adhesivity at the point where the webs are brought together with the pouches in register.

In FIGS. 17 a, 17 b, 17 c, the wetting is effected by means of nozzles 53. The nozzles 53 may be configured to apply water droplets 53 a to the external (top) surface of the lidding web 54 of sealed pouches on one former. The nozzles 53 may be calibrated to apply a controlled amount of water or other aqueous medium in a controlled pattern. The nozzles 53 may apply water droplets to that part of the external surface surrounding the sealed pouches. By this means, the risk of softening that part of the lidding web 54 that comprises part of the sealed pouches is reduced. If that part of the lidding web 54 that comprises part of the sealed pouches is over wetted, there could be a risk of partial dissolution leading to rupture of the pouch and partial or complete release of the contents. The wetted lidding web 54 is sealed to lidding web 55 of sealed pouches on the other former at sealing point 56 to form combined water soluble pouches 57. The nozzles 53 may be adjustable to alter the spacing of the water droplets. In this way the seal between the lidding webs 54, 55 can be complete or partial. In use, a partial seal permits entry of an aqueous medium between the two lidding webs 54, 55 of the combined pouch 57 to accelerate the speed of dissolution of the combined pouch in the aqueous medium.

In FIGS. 18 a, 18 b, the wetting is effected by means of a servo-controlled roller 58. The roller 58 may be configured to apply a controlled amount of water or other aqueous medium to the external (top) surface of the lidding web 55 in a controlled pattern. The roller 58 may apply water to only that part of the external surface surrounding the sealed pouches. By this means, the risk of softening that part of the lidding web 55 that comprises part of the sealed pouches is reduced. If that part of the lidding web 55 that comprises part of the sealed pouches is over wetted, there could be a risk of partial dissolution leading to rupture of the pouch and partial or complete release of the contents. The degree of adhesivity may be controlled by moving the roller 58 nearer to, or further away from, the external (top) surface of the lidding web 55 of the sealed pouches held on the former by a vacuum contained therewithin.

In FIGS. 19 a, 19 b, the wetting is effected by means of a plate 59. The plate 59 is provided with apertures 60 for applying a controlled amount of water or other aqueous medium from a supply 61 to the external (top) surface of the lidding web 54 in a controlled pattern. The plate 59 may apply water to only that part of the external surface surrounding the sealed pouches. By this means, the risk of softening that part of the lidding web 54 that comprises part of the sealed pouches is reduced. If that part of the lidding web 54 that comprises part of the sealed pouches is over wetted, there could be a risk of partial dissolution leading to rupture of the pouch and partial or complete release of the contents. The degree of adhesivity may be controlled by moving the plate 59 up and down as the lidding web 54 moves continuously towards the sealing point 56 thereby ensuring that the desired level of adhesivity is obtained.

Referring now to FIGS. 20 a, 20 b, a method and device is shown for inserting a solid object 66 such as a tablet between the lidding webs 54, 55 of the pouches held by vacuum on the formers prior to sealing or bonding the webs together, thereby forming a compartment 67 containing the solid object 66 between the lidding webs 54, 55. In FIG. 20 a, a tablet 66 is placed upon the lidding web 54 by a tablet feeder 68 allowing the tablet 66 to be subsequently sealed in the compartment 67 formed between the two lidding webs 54, 55 in the combined pouch 57. The combined pouch 57 is shown in FIG. 20 b.

An exemplary embodiment provides a machine and method of forming multi-compartment pouches in which two pouches can be formed simultaneously on separate adjacent formers and brought together in register so that the pouches can be joined to form a combined pouch. The pouches may be held on the formers by vacuum until the pouches are joined whereupon the vacuum holding one of the pouches on its former is released while maintaining the vacuum holding the other pouch on its former so that the combined pouches are held on that former by the vacuum until the vacuum is released.

While exemplary embodiments have been described, it will be understood that the invention is not limited thereto and that modifications can be made within the scope of the invention as defined in the claims. 

1. A continuous motion machine for producing water-soluble pouches comprising two or more compartments from four water-soluble polymeric webs wherein two pouches are formed, filled and sealed on separate, adjacent donating and receiving formers, each pouch being formed from two water-soluble polymeric webs, and wherein the two such pouches are held by vacuum on their formers until they are joined together in register to form a combined pouch whereupon the vacuum in the donating former is removed releasing its pouch to the receiving former and the combined pouch still held by vacuum in the receiving former is separated from the combined web.
 2. The machine according to claim 1 wherein the machine is configured to provide a partial perimetric seal between lidding webs of the two pouches.
 3. The machine according to claim 1 wherein the machine is configured to provide a complete perimetric seal between lidding webs of the two pouches.
 4. The machine according to claim 2 wherein the machine is configured to place a solid item between the lidding webs of the two pouches before the lidding webs are sealed together, thereby creating a compartment between the lidding webs.
 5. The machine according to claim 4 wherein the machine is configured such that the solid item is visible through at least one window within both webs of either or both pouches
 6. The machine according to claim 1 wherein the machine is configured to perforate a base web of at least one of the pouches.
 7. The machine according to claim 6 wherein the machine is configured to perforate the base web prior to a forming operation.
 8. The machine according to claim 6 wherein the machine is configured to perforate the base web during a forming operation.
 9. The machine according to claim 6 wherein the machine is configured to perforate the base web after a forming operation
 10. A method of producing water-soluble pouches comprising two or more compartments by forming, filling and sealing two pouches on separate, adjacent formers each from two water-soluble polymeric webs, bringing the two webs together with the two such pouches in register while they are held by vacuum on their formers and joining the two such pouches together to form a combined web and combined pouch comprising two or more compartments, and removing the vacuum in one former releasing its pouch to the other former so that the combined pouch is still held by vacuum in the other former and separating the combined pouch from the combined web.
 11. (canceled)
 12. The method according to claim 10 wherein one or more compartments contain a combination of at least two components comprising a granular or powder product, a thickened liquid or gel, and a three dimensional solid item such that all of the components retain their identity and none of the components become mutually antagonistic.
 13. The method according to claim 10 wherein a partial perimetric seal is formed between lidding webs of the two pouches.
 14. The method according to claim 10 wherein a complete perimetric seal is formed between lidding webs of the two pouches.
 15. The method according to claim 13 wherein a solid component is inserted between the lidding webs of the two pouches prior to the two pouches being sealed or bonded together, thereby creating a compartment between the lidding webs.
 16. The method according to claim 15 wherein the solid component is visible through at least one window within both webs of either or both pouches
 17. The method according to claim 10 wherein a base web of at least one of the pouches is perforated before, during or after a forming operation.
 18. The method according to claim 10 including removing the vacuum holding the separated, combined pouch on the other former.
 19. The method according to claim 10 wherein a sealing pressure between the lidding films of pouches held by vacuum on the donating and receiving formers is adjustable. 20-22. (canceled)
 23. A multi-compartment water-soluble pouch formed by combining two separate pouches, each pouch having one or more sealed compartments, wherein lidding webs of the combined pouches are joined by a perimetric seal to form a further compartment between the lidding webs of the combined pouches.
 24. The multi-compartment water-soluble pouch of claim 23 wherein the perimetric seal forms a partial seal between the lidding webs of the combined pouches. 